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      10-29-2013, 07:43 AM   #23
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Quote:
Originally Posted by shlai View Post
Thanks for you reply. I have disconnected the pipe and acutator and capped them. Do you think I should also secure the push rod as well like some friend up in the thread above did? I notice the spring of the acutator is very strong in keeping the flap open, but in case the flay may still move during spirit drive on very bumpy road.
I made a change to secure the actuator arm, but this was to help it stay closed not open. You need only to cap/block the vacuum pipe.
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      06-01-2014, 11:01 AM   #24
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Exhaust flap fix

I am a new Z4 owner with a 2011 35is that has over 70K on it. The first thing I found on the cold start was this terrible rattle from the right rear. This forced me to design a better muffler flap solution that fixes the rattle problem completely without buying a brand new muffler.

The issue in this design is that you have a heat difference that could cause the flap to become tight once the exhaust starts to flow. The designers probably made the clearances on the flap shaft a bit larger because of this. So the rattler is not from the vacuum actuator as some have noted but the flap shaft and the muffler. The vibration in the muffler system is rattling the flap when the right frequency is present. If you simply apply a slight amount of pressure to the flap shaft it will stop the rattle at any frequency.

Using a ~2" length light coil spring with closed rounded ends can do the trick (You can find these at harbor freight, See photo). Bend the ends to form a round that is slightly larger than the flap shaft diameter on both sides. Attach the spring from one side of shaft to the other by stretching it and you now have tension on the shaft. Takes only 15 minute to make and install. Add a small amount of high temp thick grease to allow the flap to rotate freely and you are done...

Hope this helps....
Thanks z4s4
PS: Anyone know where you can get a service manual for this car?
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      06-01-2014, 07:45 PM   #25
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Nice fix! Also, the previous owner really enjoyed this car...70k miles in 3years!
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      12-14-2015, 01:58 PM   #26
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Quote:
Originally Posted by z4s4 View Post
I am a new Z4 owner with a 2011 35is that has over 70K on it. The first thing I found on the cold start was this terrible rattle from the right rear. This forced me to design a better muffler flap solution that fixes the rattle problem completely without buying a brand new muffler.

The issue in this design is that you have a heat difference that could cause the flap to become tight once the exhaust starts to flow. The designers probably made the clearances on the flap shaft a bit larger because of this. So the rattler is not from the vacuum actuator as some have noted but the flap shaft and the muffler. The vibration in the muffler system is rattling the flap when the right frequency is present. If you simply apply a slight amount of pressure to the flap shaft it will stop the rattle at any frequency.

Using a ~2" length light coil spring with closed rounded ends can do the trick (You can find these at harbor freight, See photo). Bend the ends to form a round that is slightly larger than the flap shaft diameter on both sides. Attach the spring from one side of shaft to the other by stretching it and you now have tension on the shaft. Takes only 15 minute to make and install. Add a small amount of high temp thick grease to allow the flap to rotate freely and you are done...

Hope this helps....
Thanks z4s4
PS: Anyone know where you can get a service manual for this car?
This is a brilliant solution, THANK YOU very much for sharing! This should be stickied somewhere!!
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      01-05-2016, 10:24 AM   #27
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many people do the golf tee mod (search for it) but since you want the sound to be lesser on startup this wouldnt have worked for you. great job on this fix.
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      02-21-2016, 06:26 PM   #28
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Great job! Going to do it this week!
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      02-21-2016, 09:31 PM   #29
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Quote:
Originally Posted by z4s4 View Post
I am a new Z4 owner with a 2011 35is that has over 70K on it. The first thing I found on the cold start was this terrible rattle from the right rear. This forced me to design a better muffler flap solution that fixes the rattle problem completely without buying a brand new muffler.

The issue in this design is that you have a heat difference that could cause the flap to become tight once the exhaust starts to flow. The designers probably made the clearances on the flap shaft a bit larger because of this. So the rattler is not from the vacuum actuator as some have noted but the flap shaft and the muffler. The vibration in the muffler system is rattling the flap when the right frequency is present. If you simply apply a slight amount of pressure to the flap shaft it will stop the rattle at any frequency.

Using a ~2" length light coil spring with closed rounded ends can do the trick (You can find these at harbor freight, See photo). Bend the ends to form a round that is slightly larger than the flap shaft diameter on both sides. Attach the spring from one side of shaft to the other by stretching it and you now have tension on the shaft. Takes only 15 minute to make and install. Add a small amount of high temp thick grease to allow the flap to rotate freely and you are done...

Hope this helps....
Thanks z4s4
PS: Anyone know where you can get a service manual for this car?
Here you go: http://www.bmwusa.com/pdf_aa6c05ad-4...fe74d8fcc.arox Google is your friend
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Last edited by jparnes1; 02-21-2016 at 09:39 PM..
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      02-22-2016, 06:47 PM   #30
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Quote:
Originally Posted by jparnes1 View Post
I think the poster was looking for a service manual. The link was to the owners manual. I would be interested in a service manual as well.
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      02-23-2016, 06:58 AM   #31
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Quote:
Originally Posted by Jetmart View Post
I think the poster was looking for a service manual. The link was to the owners manual. I would be interested in a service manual as well.
Yeah, my bad. Here you go. But you might want to consider doing more than BMW recommends if you plan on keeping your car.
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File Type: pdf 2011_Z4_Service_warrantly_booklet.pdf (4.51 MB, 263 views)
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